Method and apparatus for artificially aging pre-cast blocks

ABSTRACT

A method and apparatus for modifying the surface texture of pre-cast building blocks including a pressure-applying device so positioned as to selectively engage blocks and being adapted to apply a pressure on the surface of blocks so as to modify their texture thereof prior to the curing of the blocks. Also disclosed is an apparatus for modifying the surface texture of pre-cast building blocks including mechanisms and structures adapted to provide a plurality of longitudinal movements and a plurality of rotational movements to adjust the direction of the wearing tool in respect to the alignment of the blocks when modifying the surface texture of these blocks as well as a block-stabilizing device for stabilizing blocks during surface-texture modification operations.

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for modifyingthe texture of a block. More specifically, the present invention isconcerned with a method and apparatus for modifying the texture of ablock before curing. The present invention also relates to a blockspacer for spacing a plurality of blocks and a block stabilizer forstabilizing blocks during surface-texture modification operations.

BACKGROUND OF THE INVENTION

Devices for artificially ageing blocks are well known in the art. Someof the prior art included block tumblers; these devices though wereinadequate because of the loss of much block material, which raisedproduction costs. Improvements were on-line devices where blocks wereconveyed under or through impacting devices for surface modification,deformation, chipping etc. thereof.

Conventional block-conveying systems include a support table for movingthe blocks thereon as they are acted on during texture surfacemodification. The following are examples of block-texture modifyingapparatuses.

Canadian Patent Application No. 2,343,338 teaches an apparatus forroughing the surfaces of concrete casted blocks. A roller having chainsattached thereon and spaced apart 5 from one another is provided aboveblocks that are being supported on a moveable table. The support tablehas a flat upper surface. The support table includes holes through whichpins are projected in order to tilt the bottom surface of the blockshence tilting the whole blocks at predetermined locations in order forthe chain to impact the blocks on their upper surface at differentlocations.

Canadian Patent Application No. 2,350,979 teaches a system for modifyingthe texture of blocks. The system includes texturing elements that areon support cables which spin and which are brought closer to the blockin order to bring the texturing elements in contact with the block forimpacting the surface. The texturing elements can be moved at differentangles in order to impact the block's surfaces in different areas duringthe translational movement of the block.

Canadian Patent Application No. 2,392,934 teaches a concrete texturemachine for modifying the surface texture of stone blocks. The machineconveys concrete blocks at a pitching station having opposed pitchingblades. Each of the blades have a forward projecting cutting edge thatare displaced towards and away from one another at predetermineddistances.

European Patent Application No. 1211036 teaches a device forartificially ageing stones. This device includes top and bottom rollerswith mangling elements that engage the edges stones passed therebetweenin order to break and mangles these edges.

A limitation of these prior art apparatuses is that they do not providefor the blocks to be spaced apart at a constant distance when acting onthem. Furthermore, these prior art apparatuses are inconvenient foracting on the edges of the blocks.

Japanese Patent Application No. 04194202 teaches a spacer whichfunctions to create a gap between mutual blocks in order to make it lookwide in external appearance. The spacer is used for the construction ofthe blocks. All the documents referred above are included herewith byreference.

The spacers and positioning mechanisms of the prior art are notconstructed for modifying pre-cast blocks.

Hence, the prior art teaches chains on a spinning longitudinal member toimpact the surface of concrete blocks; rollers for engaging the edges ofblocks as well as spacers for building and laying concrete blocks arealso known.

A general limitation of the prior art is that is does not provide anapparatus and method for maintaining the block that provides easy accessto the block edges so as to act thereon as well as various block-texturemodifying actions that modify these edges accordingly.

A drawback of such devices is that high pressure must be applied onthese blocks.

There thus remains a need for an improved apparatus and method formodifying the surface texture of blocks.

SUMMARY OF THE INVENTION

More specifically, in accordance with the present invention there isprovided a method for modifying the surface texture of pre-cast buildingblocks, said method comprising: (a) pressing cementitious materialwithin a mould into pre-cast blocks; (b) applying pressure on thesurface of pre-cast blocks obtained in step (a) so as to modify thetexture thereof; and (c) providing for curing of pre-cast blocksobtained in step (b).

In an embodiment, the method further comprises after (c): (d) applyingpressure on the surface of pre-cast blocks after curing so as to furthermodify the texture thereof. In an embodiment, step (b) comprisesapplying pressure on the top edges of pre-cast blocks. In an embodiment,said pressure in (b) is applied via a pressure-applying member. In anembodiment, said pressure applying member comprises a longitudinal rodmember. In an embodiment, said longitudinal rod member comprises ridgeson its outer surface. In an embodiment, said pressure in step (b) isapplied via air-pressure. In an embodiment, said pressure is step (d) isapplied by a block-texture modifying device. In an embodiment, said step(b) creates weak areas on the surface of blocks. In an embodiment,pressure in step (d) is applied on said weak areas.

In accordance with another aspect of the invention there is provided anapparatus for modifying the surface texture of pre-cast building blocks,said apparatus comprising a support for supporting blocks thereon, apressure-applying device so positioned as to selectively engage blockson said support, wherein said pressure-applying device is so adapted asto apply a pressure on the surface of blocks so as to modify the texturethereof before curing of said blocks.

In an embodiment, the apparatus further comprises a translationalmovement-imparting device from imparting a translation movement betweenblocks on said support and said pressure-applying device. In anembodiment, the translational movement imparting device comprises a pushmember, said push member comprising a block-engaging member and beingconnected to an actuator for translational movement thereof. In anembodiment, said translational movement imparting device comprises aconveyor for translationally conveying said support with blocks thereon.In an embodiment, said pressure-applying device is moveable between ablock engaging position and a block disengaging position. In anembodiment, said pressure-applying device is adjacent to a press andmould apparatus for pressing cementitious material into pre-cast blocks,said pressure-applying device being so positioned as to engage thesurface of blocks after said pressing. In an embodiment, said pressureapplying device comprises a longitudinal rod member. In an embodiment,said longitudinal rod member comprises ridges on its outer surface. Inan embodiment, said pressure applying device comprises a lateral rodmember. In an embodiment, said longitudinal rod member comprises ridgeson its outer surface. In an embodiment, said pressure-applying devicecomprises longitudinal members and lateral members crossing saidlongitudinal members so as to form individual generally rectangularmembers for engaging the edged perimeter of blocks. In an embodiment,said longitudinal and lateral members comprise respective rod membershaving ridges on their respective outer surfaces. In an embodiment, saidpressure-applying device comprises an air blower for applying airpressure on blocks. In an embodiment, the apparatus further comprises ablock-texture modifying device for further modifying the surface textureof blocks after both initial modification of blocks by saidpressure-applying device and curing thereof.

In accordance with a further aspect of the invention, there is provideda spacer for spacing adjacent blocks apart at a pre-determined distancewhen modifying the surface texture of these blocks, said spacercomprising spacing elements for placing between adjacent blocks.

In an embodiment, said spacing elements comprises crossed membersdefining individual areas for receiving a given block therethrough. Inan embodiment, said spacing elements are so configured as to expose thetop and bottom edges of blocks. In an embodiment, said spacing elementsare of a substantially equal thickness, said receiving areas being ofsubstantially equal sizes. In an embodiment, said spacer comprisesperipheral enclosing members for enclosing a plurality of blockstherein. In an embodiment, said enclosing elements are so configured asto expose the top and bottom edges of blocks. In an embodiment, saidspacer comprises four peripheral enclosing members defining a generallyrectangular shape, longitudinal spacing members extending betweenopposite said peripheral enclosing member, said spacing membersextending between one pair of opposite enclosing members crossing saidspacing members extending between another pair of opposite enclosingmembers thereby defining individual receiving areas, each said receivingareas are configured to receiving a block therein.

In accordance with yet another aspect of the present invention, there isprovided block-stabilizing device for stabilizing blocks duringsurface-texture modification operations, said device comprising aplurality of stabilizing members for respectively engaging a portion ofblock surfaces thereby exposing another portion of block surfaces,wherein each said stabilizing member exerts sufficient pressure on ablock so as to substantially avoid movement thereof duringsurface-texture modification operation on said exposed block surfaceportion.

In an embodiment, each of said stabilizing members comprises a plaque.In an embodiment, said plaques are mounted to supports. In anembodiment, said supports are mounted to actuators so at to move saidplaques between block engaging and disengaging positions. In anembodiment, said exposed block surface portion comprises the edgedperimeter of blocks.

In another embodiment, a block-stabilizing device for stabilizing blocksduring surface-texture modification operations is provided, said devicecomprising a plurality of stabilizing members for respectively engaginga portion of block surfaces thereby exposing another portion of blocksurfaces, wherein each said stabilizing member exerts sufficientpressure on a block so as to substantially avoid movement thereof duringsurface-texture modification operation on said exposed block surfaceportion.

Another embodiment provides an apparatus for modifying the surfacetexture of pre-cast building blocks the apparatus comprising a primaryframe defining a longitudinal axis between a forward portion and arearward portion, a tool holder, defining a tool holder axis, moveablyconnected to the frame, a first motor supported by the frame fordisplacing the tool holder along the longitudinal axis, and a secondmotor supported by the frame for rotating a wearing tool about a wearingtool axis, the wearing tool supported by the tool holder and adapted torotate about the tool holder axis.

An advantage of the present invention is that it provides a method andapparatus for modifying the surface texture of blocks using lesspressure than prior art devices and methods.

Other objects, advantages and features of the present invention willbecome more apparent upon reading of the following non-restrictivedescription of embodiments thereof, given by way of example only withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the appended drawings:

FIG. 1 is front elevational view of the apparatus for modifying thesurface texture of pre-cast building blocks in accordance with anembodiment of the present invention;

FIGS. 2 to 5 are perspective views of the operation of thepressure-applying device in accordance with an embodiment of the presentinvention as well as the support of the apparatus of FIG. 1.

FIG. 6 is an enlarged perspective partial view of the pressure-applyingdevice of FIG. 1

FIG. 7 is an enlarged perspective view of the blocks of FIG. 5 afterhaving been treated by the apparatus of FIG. 1;

FIG. 8 is a schematic front view of the apparatus for modifying thesurface texture of pre-cast building blocks in accordance with anotherembodiment of the present invention;

FIG. 9 is a top plan view of a block surface-texture modifying device inaccordance with an embodiment of the invention;

FIG. 10 is a top plan view of a block surface-texture modifying devicein accordance with another embodiment of the invention;

FIG. 11 is top plan view of a block stabilizing device in accordancewith an embodiment of the invention;

FIG. 12 is a side elevation view of a block modification device of FIG.10;

FIG. 13 is a front elevation view of a portion of the block modificationdevice of FIG. 12;

FIG. 14 is a front elevation view of a portion of the block modificationdevice of FIG. 12;

FIG. 15 is a front elevation view of a portion of the block modificationdevice of FIG. 12;

FIG. 16 is a section view of a series of blocks spaced apart by aspacer;

FIG. 17 is a combined side and front elevational views of anotherembodiment of the invention;

FIG. 18 includes a side elevational view and a top plan view of aportion in addition of various parts of the embodiment depicted on FIG.17;

FIG. 19 includes side elevational views and a top plan view of a portionof the embodiment depicted on FIG. 17;

FIG. 20 is a combined side and front elevational views and top plan viewof the embodiment depicted on FIG. 17

FIG. 21 is a combined side and front elevational views of a portion ofthe embodiment depicted on FIG. 17

FIG. 22 is a combined side elevational view and top plan view of aportion of the embodiment depicted on FIG. 17

FIG. 23 is a combined side and front elevational views of a portion ofthe embodiment depicted on FIG. 17 and

FIG. 24 is a combine side and front elevational views and top plan viewof a portion of the embodiment depicted on FIG. 17

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

With reference to the appended drawings an embodiment of the inventionwill be herein described so as to exemplify the invention and not limitits scope.

FIG. 1 shows an apparatus 10 for modifying the surface texture ofpre-cast building blocks 12 which are mounted on a support 14.

Apparatus 10 includes a pressure-applying device 16 positioned abovesupport 14. The pressure-applying device 16 is movable between a blockdisengaging position as shown in FIGS. 1 and 2 and a block engagingposition as shown in FIGS. 3 and 4. Returning to FIG. 1, thepressure-applying device 16 is mounted to actuators 18 and 20, which canbe hydraulic motors, for movement between the block engaging anddisengaging positions.

As shown in FIG. 2 to FIG. 6, the pressure applying device 16 includeslateral and longitudinal pressure applying members 22 and 24respectively which are rod elements having ridges 26 thereon. A blockstabilizing device 82 is also disclosed and is used in conjunction withthe pressure applying device 16 to maintain the blocks 12 in place. Theblock-stabilizing device 82 is sized and designed to mate with thepressure applying device 16. Each contact pad 86 are disposed on theblock-stabilizing device 82 to be aligned with a corresponding openingon the pressure-applying device 16 when the block-stabilizing device 82is disposed above the pressure-applying device 16. A leg 84 connects thecontact pad 86 to the block-stabilizing device 82 and providessufficient space to move the pressure-applying device 16 between theblocks 12 and the block-stabilizing device 82 still contacting theblocks 12.

Illustratively, in operation, the block-stabilizing device 82, while thepressure applying device 16 is disposed between the block-stabilizingdevice 82 and the blocks 12, is moved in contact with the series ofblocks 12. Each block 12 is thus maintained in place by the pressurefrom the pads 86. Then, the pressure applying device 16 is moved towardthe series of blocks 12 in contact with the blocks 12 while theblock-stabilizing device 82 still ensures the series of blocks do notmove. The pressure applying device 16 imprints the blocks and is movedaway from the blocks 12. Once the pressure applying device 16 is movedaway from the series of blocks 12, the block-stabilizing device 82 isthen moved away from the series of blocks 12.

As shown in FIG. 2 to FIG. 7, right after the blocks 12 are formed bypressing cementitious material in moulds as in known in the art, theblocks 12 being still humid will be pressed by the pressure applyingdevice 16. The lateral member 22 will press two edges of two adjacentblocks and the longitudinal member 24 will press two edges of twoadjacent blocks as well.

More specifically, element 24 engages top adjacent lateral edges 28 and30 of two adjacent blocks 12A and 12B while element 22 engages therespective top back edge and top front edge 32 and 34 of two adjacentblocks 12B and 12C. As shown in FIG. 1, the device 16 engages blocks 12on support 14 via the actuators 18 and 20, which move thepressure-applying device 16 in a up and down movement in a verticaldirection as shown by arrows U and D respectively.

Once blocks are molded from cimentitious material, they can be movedunder a pressure applying device 16 via translational movement impartingdevice such as a support 14. Of course other ways of moving blocks alonga support such as shown in FIGS. 9 and 10 can be contemplated within thescope of the present invention. For examples, in FIG. 9 and FIG. 10,there is shown a push member 36 having a block engaging member 38 andbeing powered by an actuator (not shown).

In another embodiment, that can be deducted from FIGS. 2 to 5, thepressure applying device 16 can be moved manually by workers in order topress on the surface texture of still humid blocks 12 after blocks 12have been formed.

In another embodiment, shown in FIG. 8, the pressure-applying device 40comprises air blowers 42. The air blowers 42 are actuated so as toengage and disengage blocks 12. Hence when the air blowers 42 areactuated to engage blocks 12 they engage these blocks via air pressuredenoted by numerical reference 44. Specifically, the air blowers 42 blowair 44 onto the top surface 13 of blocks 12. As shown in FIG. 8, the airblowers 42 can be so positioned as to blow at the top edges 28 and 30, ablower 42A can be so positioned as to apply air pressure 44 onto theadjacent edges 28 and 30 of two adjacent blocks 12D and 12E.

With particular reference to FIG. 7, the contoured edge 46 of freshlypressed blocks 12 has had its surface texture modified or made weak. Theforegoing modification or imparted weakness, allows the blocks aftercomplete curing to have those same contoured edges 46, or any other liketreated surface texture, be easily broken and modified by surfacetexture modification apparatuses in order to artificially age theseblocks.

With reference to FIGS. 9 and 10, there is shown block surface texturemodification apparatuses 48 (see FIG. 9) and 50 (see FIG. 10). Theapparatuses 48 and 50 are described in Canadian application No.2,509,064 filed on Jun. 2, 2005 and in U.S. application Ser. No.11/144,193 filed on Jun. 3, 2005, these documents are incorporatedherein by reference. Generally the blocks are spaced by a spacer 52. Itshould be noted that the spacer 52 can also be used as apressure-applying device as well. For example, when placing the spacer52 onto the blocks 12 in order to space them apart, the spacer 52 willengage the top edges of still humid blocks 12, or any other surfacethereof, similar to the way the pressure applying device 16 does, asshown in FIGS. 2 to 4.

The blocks 12 are moved along the support 53 by push members 36 in orderto be engaged by block modification devices 54A, 54B

This way, the block modification apparatuses described above can engagethe modified or weakened contoured edge 46, or any other like treatedsurface after the blocks 12 have gone through curing and thesepre-modified surfaces can be easily modified with less pressure orimpact by surface-texture modifying devices since the pre-modifiedsurfaces have been broken or deformed right after the blocks were moldedby the pressure applying devices and methods disclosed above.

With reference to FIG. 11, there is shown a block-stabilizing device 60.This block-stabilizing device 60 comprises a plurality of optionalplaques 62 of varying sizes and shapes that are connected to each otherby connecting member 64. Connecting members 64 are connected to supports66A and 66B at each of their longitudinal ends. These supports 66A and66B are mounted to actuators 68A and 68B respectively for verticalmovement thereof between block disengaging and block engaging positions.

Plaques 62 are used to engage blocks 12 and apply pressure thereon. Theplaques 62 cover most of the top surface of 13 of a block 12 yet exposeits outer perimeter or contoured edge 46 thereby providing for a varietyof block modification devices to engage this exposed contoured edge suchthat the various block modification devices can modify the texturesurface of the exposed perimeter or contoured edge 46.

Still referring to FIG. 11, the block-stabilizing device 60 could beused without the plurality of plaques 62. The contact with the blocks 12is directly made with the connecting members 64. The exposed surface ofthe block 12 is greater when no plaque 62 is used. The blockmodification devices 54 have access to the top surface to alter thetexture.

The direction of the connecting members 64 is orthogonally disposed inrespect with the axis of rotation of the block modification devices 54.The block modification devices 54 can perform the action on the seriesof blocks 12 using rotative tools without crossing the connectingmembers 64. Once the series of blocks 12 has been modified in a firstdirection the connecting member is removed and turned at a 90° angle.The block modification devices 54 can perform the action in the seconddirection, orthogonal to the first direction, to complete modifying thetexture on each side of the blocks 12.

FIGS. 9, 10 and 12 show a multi-station block texture modifyingapparatus 54. This apparatus 54 includes a support 53 for supporting aplurality of blocks 12 thereon. In this embodiment, there are twomulti-station block texture modifiers 54A and 54B. In other embodiments,apparatus 54 may include one or more multi-station block texturemodifier. In this embodiment, each multi-station block texture modifier54 respectively includes a pressure-applying station 56, an impactingstation 57, and a polishing station 58. In this embodiment, stations 56,57 and 58 are in an upstream arrangement.

In accordance with this embodiment, the multi-station block texturemodifier 54 may include only a pressure-applying station 56 and animpacting station 57. Furthermore, in another embodiment, the impactingstation 57 can be upstream of the pressure-applying station 56.

The multi-station block texture modifying apparatus 54 also includes atranslational displacer (push member 36) for imparting translationaldisplacement between blocks 12 on the support 53 and the multi-stationblock texture modifier 54.

In this embodiment, the support 53 is a table that provides for theplurality of blocks 12 to be moved thereon through the multi-stationblock texture modifier 54. As shown in FIGS. 13, 14 and 15 support 53includes longitudinal separate panels that are so spaced apart as toexpose the bottom edges of blocks 12 as will be further explained below.

The translational displacer 36 is a push member. The push member 36 hasone end (not shown) mounted to an actuator (not shown) for translationalmovement thereof, and a free block engaging end for pushing the engagingblocks 12 or a plurality of blocks 12 on the support and through themulti-station block texture modifier 54.

In another embodiment, the translational displacer can comprise aconveyor as is understood by the skilled artisan to displace blocks 12relative to the modifier 54. Still in a further embodiment, thetranslational displacer can comprise a wide variety of actuationassemblies for displacing the modifier 54 relative to immobile blocks12. In this embodiment, the modifier 54 can be displaced as a unit orits stations 56, 57 and 58 can be displaced separately. Furthermore,combinations of push members 36, conveyors and actuators to displacemodifier 54 and/or its stations 56, 57 and 58 can also be contemplatedwithin the scope of the present invention.

As shown in FIGS. 12 through 16, the blocks 12 are spaced apart by aspacer 52. As more clearly shown in FIG. 9, this spacer 52 is arectangular-shaped grid and comprising spacing members in the formhorizontal cross lateral members and longitudinal members therebycreating receiving areas for receiving blocks 12 therethrough.Longitudinal spacer members extend between opposite enclosure members,whereas longitudinal spacer members extend between opposite enclosuremembers for a plurality of blocks 12 to be moved together on the support53. Furthermore, the grid spacer 52 provides for the blocks 12 to bespaced from each other at a predetermined constant distance. As bettershown in FIG. 16, and as will be explained later, the top edges andbottom edges 73 of two adjacent blocks 12 are kept apart at apredetermined constant distance allowing for the multi-station blocktexture modifier 54 to modify edges 73, as will be explained herein.

As better shown in FIG. 12, and as aforementioned, the multi-stationblock texture modifier 54 includes a pressure-applying station 56, animpacting station 57, and a polishing station 58.

Turning to FIG. 13, there is shown the pressure-applying station 56,which serves to apply a sustained pressure to blocks 12 that are engagedthereby. The pressure-applying station 56 includes pressure-applyingelements 72, which engage the blocks 12 in order to apply a sustainedpressure to the texture surface of the blocks 12 so that this texturesurface is modified.

In the embodiment shown here, the pressure-applying elements 72 are toprollers mounted along a top rotating longitudinal member 74, thepressure-applying elements 72 are bottom rollers mounted along bottomlongitudinal member 72, and so positioned as to respectively engage thetop and bottom opposite edges 73 of blocks 12. As shown, a single givenroller 72 of the top member 74 engages two opposite edges 73 of twoadjacent blocks 12 and a single given roller 72 of the bottom member 74engages two opposite edges 73 of two adjacent blocks 12. In thisillustrative example the top and bottom rollers are collinear. The topand bottom longitudinal members 74 are actuated by motors 70 to changetheir relative distance.

As aforementioned, the support surface 53 also includes separatevertical members 53, which are so spaced apart as to expose the bottomedges 73 of block 12, so they can be engaged by the multi-station blocktexture modifier 54.

The top moveable member 74 or bottom member 74 can be moveable in anupward or downward fashion, as shown by arrow Y in order to modulate thepressure applied by a roller 72 mounted thereon. In another embodiment,the rollers 72 may be expandable, again in order to modulate thesustained pressure applied to the texture surface of the blocks 12. Theforegoing features are described in PCT publication WO/2004078441, whichis incorporated herein by reference.

In an embodiment, the pressure-applying station 56 may comprise only toppressure applying elements 72. In another embodiment, thepressure-applying station 56 may comprise only bottom pressure applyingelements 56.

Turning now to FIG. 14, there is shown an impacting station 57, whichincludes top and bottom impacting elements 77. In this example, theseimpacting elements 76 are chains extending from a rotating member in theform of a rod 76 that is mounted to an actuator in order to rotate aboutits longitudinal length, hence, actuating the chains 77 so that theyspin in the clockwise direction shown by arrow R, of course the chains77 can also be spun in a counter-clockwise direction, in order to impactthe texture surface of blocks 12. In this example, it is the top andbottom edges 73 of the blocks 12 which are respectively impacted by thechains 77. A shown, a given top impacting element 77 is so position asto simultaneously impact the adjacent top edges 73 of two adjacentblocks 12 and a given bottom impacting element 77 is so position as tosimultaneously impact the adjacent bottom edges 73 of two adjacentblocks 12. In this example the top and bottom-impacting element 76 arecollinear. In an embodiment, the impacting station 57 may comprise onlytop impacting elements 76, in another embodiment the impacting station57 may comprise only bottom impacting elements 76. Of course impactingelements 76 can comprise any type of protrusion member for impacting thesurface texture of blocks 12 as will be understood by the skilledartisan. A variety of such impacting elements are described in PCTpublication WO/2004078441.

With respect to FIG. 15, there is shown the polishing station 58, whichincludes top and bottom polishing members 80. These top and bottompolishing members 80 are respectively mounted along a top and bottomrotating members 74. Rotating longitudinal members 74 are operativelymounted to motors 70 so as to be actuated to rotate about theirrespective longitudinal axes. In this way, the top polishing member 80will rotate along the axis formed by member 74 and the bottom polishingmember 80 will rotate along the axis formed by member 74. in thisexample, the polishing members 80 are in the form of brushes; brushes 80are so spaced along their respective top or bottom members 74 so as torespectively engage the top edges 73 and bottom edges 73 of blocks 12.As shown, a single given top brush 80 engages two edges 73 of twoadjacent blocks 12 and a single given bottom brush 80 engages two edges73 of two adjacent blocks 12. In an embodiment, the polishing station 58may comprise only top polishing elements 80 or only bottom polishingelements. Of course a variety of polishing or brushing elements as isunderstood by a skilled artisan can be used.

With respect to FIG. 16, it should be noted that the spacer 52 providedfor spacing the blocks 12 at a predetermined and constant distances, theblocks 12 are laterally displaced relative to each other and thisdistance is provided by the width or thickness of members 52. In thisway the modifier 18 has easier access to the edges 73.

Referring now to FIG. 17 depicting an additional embodiment. Theapparatus for modifying the texture of pre-casted blocks 110 includes aprimary frame 114 and other elements supported by the primary frame 114.Steel members are used to build the primary frame 114 and are adaptedfor supporting a secondary frame 118 moveable along a longitudinal axis116. The top portion of the primary frame 118 is designed such that therail members 120 offer proper support for the wheels 134 of thesecondary frame 118. The secondary frame 118 supports a tool holder 138that is adapted for receiving a tool frame 154 on its lower portion.Longitudinal movements of the secondary frame 118 move the tool holder138 and the tool frame 154 connected hereto. The tool holder 138 definesa tool holder axis 128 and is adapted retract or extend to change theposition of the tool frame 154. Additionally, rotational (360° and more)or pivotal (less than 360°) movements of the tool holder 138 about thetool holder axis 128 changes the angle of the tool frame 154. A pivot,preferably disposed between the tool holder 138 and the tool frame 154,could allow pivotal or rotational movements of the tool frame 154 aboutthe tool holder axis 128 thus avoiding the tool holder 138 to rotate orpivot about the tool holder axis 128. All rotation or pivotal movementsof the tool frame 154 and the tool axis 158 about the tool holder axis128 or the longitudinal axis 116 are considered within the realm of thepresent application.

The movements of the apparatus of FIGS. 17-24 are illustrativelyassisted by electric motors. A first motor 130, affixed to the secondaryframe 118, moves longitudinally on the secondary frame 118. A secondmotor 126, also affixed to the secondary frame 118, provides arotational or a pivotal movement to the tool holder 138. A third motor122, connected on top of the tool holder 138, changes the length of thetool holder 138. Each motor 130, 126, 122 has variable speed and isoperatively coupled to its respective associated elements using either agearbox, a chain and sprocket mechanism, a lever or a pulley and beltconnection. Other means for moving portions of the apparatus that areknown in the art of designing industrial and manufacturing machines,such as hydraulic cylinders or linear positioning servo motors, arewithin the scope of the present application.

Each motors 130, 126, 122 are electronically managed by a computer orother programmable means for obtaining the desired wearing effect on theblocks 12. The combined movements of the apparatus' moveable members arecoordinated by the computer to get a weathered, or aged, look on thepre-casted blocks 12. The linear movements, the height, the angle andthe rotational speed of the wearing tool 166 are combined and varyaccording to an algorithm. The algorithm is interpreted by the computerand may be modified to change the desired aged-look of the pre-castedblocks. Slight continuous modifications to the tool axis 158 angle aboutthe tool holder axis 128 while moving the secondary frame 118 along thelongitudinal axis 116 with a spinning wearing tool 166 contacting theblocks 12 procure a random aged-look to the blocks 12.

The lower portion of the tool holder 138 discussed above is adapted forreceiving a tool frame 154. The connection between the tool holder 138and the tool frame 154 uses an arrangement of pivots 142 and damper 146.This arrangement of pivots 142 and damper 146 reduces the amount ofvibrations generated by the wearing tool 166, supported by the toolframe, that is connected to the tool holder 138. The lower portion ofthe tool holder 138 is designed for easily changing the tool 166 infavor of various other tools (not shown) including, but not limited to,chipper, blades, brushes, rollers and hammers. Chipper and hammer toolscan be used to completely cut a block 12 in smaller blocks.

An illustrative tool 166 is shown on FIGS. 17 and 23. The tool 166mounted on the tool frame 154 comprises a central portion 156 defining atool axis 158. The illustrative tool 166 is rotatably connected on eachside to tool frame 154 with bearings or bushings 160. A pair ofadditional electric motors 150 is affixed to the tool frame, on eachside of the tool frame 154, and operatively connected to the centralportion 156 via sprockets 152. A series of wearing means, illustrativelychains 166. are fastened 168 to the central portion 156. The centralportion's 156 rotation induces movement to the chains 166 used torepetitively hit the blocks thus changing the texture of the blocks. Thedistance between the chains 166 is adjustable by moving the fasteningmeans 168 along the central portion 156. A key 172 ensures the fasteningmeans 168 do not rotate with the central portion 156. Other means forpositioning the fastening means appearing obvious to the skilled readerare encompassed by the present application.

The blocks are disposed on a block support 162 under the primary frame114. The block support 162 is of sufficient size to accommodate a seriesof blocks. The height of the block support 162 can be adjusted with theactuator 164. Each block is maintained on the block support 162 by ablock-stabilizing device for stabilizing blocks during surface-texturemodification operations. The block-stabilizing device comprises aplurality of linear stabilizing members. Each linear stabilizing memberillustratively contacts the center of the top portion of a row of blocksleaving uncovered each lateral side portion of the blocks. The pressureexercised by the linear stabilizing member is sufficient to prevent anymovement of the blocks during the surface-texture modificationoperations.

The linear stabilizing members disposed in the longitudinal direction116, when the tool axis 158 is perpendicular to the longitudinal axis116, allow the rotatable tool 166 to hit the blocks without hitting thestabilizing members. When the third electric motor 122 is activated tochange the angle of the tool holder of illustratively about 90°, toolaxis 158 is moved parallel to the orientation of the linear stabilizingmembers. A lift system changes the orientation of the linear stabilizingmembers (of about 90° angle in the present situation) to position thetool axis 158 normal to the orientation of the linear stabilizingmembers and avoid any contact between the wearing tool 166 and thelinear stabilizing members.

Referring to FIG. 18, the second motor 126 connected to the secondaryframe 118 uses a gear reduction mechanism 124 to connect the tool holder138. A link 127 having a ball joint on each side connects the gearreduction mechanism 124 to a lever 140 disposed on the tool holder 138.

Now referring to FIG. 19, it can be appreciated that the tool holder 138includes two members sliding one on the other to provide a telescopicmechanism. The third motor 122 influences the length of the tool holder138 by rotating a screw 132. The movement of the screw 132 moves theinternal wall 136 affixed inside the internal member of tool holder 138.The electric motor 122 is connected to the outside member of the toolholder 138 as opposed to the internal wall 136 that is welded into theinternal member of the tool holder 138.

It is to be understood that the invention is not limited in itsapplication to the details of construction and parts illustrated in theaccompanying drawings and described hereinabove. The invention iscapable of other embodiments and of being practised in various ways. Itis also to be understood that the phraseology or terminology used hereinis for the purpose of description and not limitation. Hence, althoughthe present invention has been described hereinabove by way ofembodiments thereof, it can be modified, without departing from thespirit, scope and nature of the subject invention as defined in theappended claims.

1. A method for artificially aging the surface texture of pre-castbuilding blocks said method comprising: (a) pre-casting said buildingblocks by pressing cementitious material within a mould resting on apallet, said mould having a pattern of side walls defining the shape andspacing of an array of pre-cast blocks; (b) removing the mould to revealsaid array of pre-cast blocks spaced apart on the pallet as per thepattern of side walls of the mould; (c) providing for curing of saidarray of spaced apart pre-cast blocks obtained in step (b); (d)immobilizing said array of cured and spaced apart pre-cast blocks in aholding device which presses the pre-cast blocks against the pallet andexposes at least a portion of each of the array of pre-cast blocks; (e)artificially aging the exposed surface of each pre-cast block bysubmitting the exposed surface to a movable wearing tool.
 2. A methodaccording to claim 1, wherein step (a) comprises pressing thecementitious material with a press head having a predetermined shapeimparting an aged look to the pressed surface of cementitious material.3. A method for artificially aging the surface texture of pre-castbuilding blocks said method comprising: (a) pre-casting said buildingblocks by pressing cementitious material within a mould resting on apallet, said mould having a pattern of side walls defining the shape andspacing of an array of pre-cast blocks; (b) removing the mould to revealsaid array of pre-cast blocks spaced apart on the pallet as per thepattern of side walls of the mould; (c) immobilizing said array ofspaced apart pre-cast blocks in a holding device which presses thepre-cast blocks against the pallet and exposes at least a portion ofeach of the array of pre-cast blocks; (d) artificially aging the exposedsurface of each pre-cast block by submitting the exposed surface to amovable wearing tool; and (e) providing for curing of said array ofspaced apart pre-cast blocks obtained in step (d).
 4. A method accordingto claim 1, wherein steps (d) and (e) are repeated while exposing andartificially aging a new portion of the pre-cast blocks.